Polaris sportsman 500 HO repair

Yes, please check. I've heard good things about caltric, and Rick's, as well as Electrosport.

Since this machine had a brand new battery ruined, I'm hoping it's just the regulator. I'll run extra grounding wires to be certain, even though the ATV is entirely rust free

 

Sheww!
Glad i drink Dos Equis!

 

I've had good luck with Rick's stuff...good warranty too.

 

Looks like they’ve taken action on the name front.


Lol!!

 

That’s awesome! Literally lol.

 

The parts I put on my cousins quad were in fact Elecrosport units. It's been a little over 2 years, no issues so far.

 

Good to hear. They are one of the inexpensive aftermarket brands

 

While at my buddy's place yesterday, I checked out the sportsman. It's an early release 04 model. Not an 05 model as I stated earlier. Made in March of 03.

We also hooked up my jump pack to the ATV, to check hours and miles. It had just under 800 miles on it. Hours were like 600. That's it.

I got the part number for the regulator, and it looks like the ones I posted above. We didn't have time to test the stator, as I had to get home and unload and stack the load of wood I brought home.

I'll need to read up on how to test the stator. But if that checks out, then this will be a $30 regulator a new agm battery, and an oil change away from having another workhorse down here.

We'll change out the diff lubes, top off the antifreeze, hit all the grease zerks, and whatever else needs to be done while we're at it.

 

The 3 yellow wires coming out of the engine are the ones you need to be concerned with...they should have no continuity to ground, but all 3 should have good continuity with each other. You can do the factory suggested resistance test, but IME that will tell you lies about 50% of the time...to me a voltage output test means much more...you are testing AC output between the wires. 1-2, 1-3, 2-3, I don't know if Polaris gives the voltage test specs or not...I know it used to be a big secret with Honda until about the mid ninety's. Anyways, a ball park number would be 20-30VAC at idle, and roughly double that when revved up. (unless you can find model specific voltage output specs, this should be in the ballpark)
And as I mentioned before...I don't know if that particular model voltage regulator needs to be grounded by its mount or not, but it does appear to use its mounting as a heat sink, so you will want to get it bolted back where it belongs.

I've never personally used these guys, but they seem to have a killer warranty, and appear to make a premium product that in some cases address's OEM problems/shortcomings.
Generator Stator for Polaris ATP 500 Hawkeye 400 HO Ranger 400 425 500 Scrambler 500 Sportsman 400 450 500 HO 2004-2014

 

2 year warranty and free exchange? Sounds very good. Here's the regulator from them for my quad. $70
Voltage Regulator for Polaris Sportsman 400 500 600 700 / Magnum 500 / Scrambler 500 / ATP 500 / Ranger 500 2003 2004

 

I got to fix this finally. I bought a new regulator/ rectifier off of Amazon for $20. The bullet connectors were a tiny bit too small, but I used a small flathead screwdriver to widen the space. It worked perfectly. I then used electrical tape to ensure the connections didn't come apart.

Here's the one that the repair guy put in up north. My mom was using my ATV and she found some guy, a hack IMHO, that tried to put this rectifier/regulator into it. It's not the stock style, so maybe it would work. IDK, I just know that this one fried a new battery. That tells me that the regulator wasn't working and sent too much voltage to the battery.




Here's the stock style. Before I mounted the unit to the frame.

And mounted.. the repair guy up north lost the bolts to mount this. So I found nuts and bolts that worked.

I put the new battery in, and changed the oil. I need to monkey with the cables as the new battery has terminals on the wrong side, easy enough to fix, but the winch can't be hooked up until I adjust this.

The low speed jet must be a bit clogged from sitting. It did get better riding it around, with some fuel system cleaner in it, and a fresh bit if gas, but it probably needs the carb taken off and cleaned up properly. It's running though, so I can use it to haul some firewood. I'll get a better picture of the whole ATV in the next few days.